阅读说明：本技术 具有横向分段的燃料电池的燃料电池管 (Fuel cell tube with laterally segmented fuel cells ) 是由 E·多姆 R.格特勒 Z·刘 C·奥斯本 于 2019-04-30 设计创作，主要内容包括：本公开的各种实施方案提供了一种燃料电池管,其包括一个或多个横向分段的燃料电池,每个燃料电池包括彼此电隔离的多个燃料电池部分。当组装成燃料电池堆时,管互连件经由它们各自的横向分段的燃料电池电连接至相邻的燃料电池管。使用横向分段的燃料电池来产生燃料电池管至燃料电池管的电连接能够实现对相邻的燃料电池管之间的电连接的更精确的测试。(Various embodiments of the present disclosure provide a fuel cell tube comprising one or more laterally segmented fuel cells, each fuel cell comprising a plurality of fuel cell portions electrically isolated from each other. When assembled into a fuel cell stack, the tube interconnects are electrically connected to adjacent fuel cell tubes via their respective laterally segmented fuel cells. The use of laterally segmented fuel cells to create fuel cell tube-to-fuel cell tube electrical connections enables more accurate testing of electrical connections between adjacent fuel cell tubes.)

1. A segmented series solid oxide fuel cell system comprising:

A first fuel cell tube comprising:

A substrate having a first end and an opposing second end, a first major surface extending between the first end and the second end, and an opposing second major surface extending between the first end and the second end; and

A plurality of fuel cells disposed on the first major surface, each fuel cell extending across the first major surface and being positioned between the first end and the second end, wherein a first selected fuel cell of the plurality of fuel cells on the first major surface that is closest to the first end is laterally segmented such that a first lateral end of the first selected fuel cell is electrically isolated from a second lateral end of the first selected fuel cell; and is

Wherein an inner selected fuel cell of the plurality of fuel cells is a fuel cell adjacent to the first selected fuel cell;

wherein the selected interior fuel cell of the plurality of fuel cells is laterally segmented such that a first lateral end of the selected interior fuel cell is electrically isolated from a second lateral end of the selected interior fuel cell;

a second fuel cell tube comprising:

A substrate having a first end and an opposing second end, a first major surface extending between the first end and the second end, and an opposing second major surface extending between the first end and the second end; and

A plurality of fuel cells disposed on the first major surface, each fuel cell extending across the first major surface and being positioned between the first end and the second end, wherein a first selected fuel cell of the plurality of fuel cells on the first major surface that is closest to the second end is laterally segmented such that a first lateral end of the first selected fuel cell is electrically isolated from a second lateral end of the first selected fuel cell; and

A first tube interconnect electrically connecting a first lateral end of a first selected fuel cell of the first fuel cell tube to a second lateral end of a first selected fuel cell of the second fuel cell tube.

2. The segmented series solid oxide fuel cell system of claim 1, further comprising a second tube interconnect electrically connecting a second lateral end of a first selected fuel cell of the first fuel cell tube to a first lateral end of a first selected fuel cell of the second fuel cell tube.

3. The segmented series solid oxide fuel cell system of claim 1, further comprising:

The second fuel cell tube, wherein a second selected fuel cell of the plurality of fuel cells on the first major surface that is closest to the first end is laterally segmented such that a first lateral end of the second selected fuel cell is electrically isolated from a second lateral end of the second selected fuel cell; and is

The second fuel cell tube, wherein a first inner selected fuel cell of the plurality of fuel cells is a fuel cell adjacent to the second selected fuel cell;

The second fuel cell tube, wherein the first interior selected fuel cell of the plurality of fuel cells is laterally segmented such that a first lateral end of the first interior selected fuel cell is electrically isolated from a second lateral end of the first interior selected fuel cell;

A third fuel cell tube comprising:

a substrate having a first end and an opposing second end, a first major surface extending between the first end and the second end, and an opposing second major surface extending between the first end and the second end; and

A plurality of fuel cells disposed on the first major surface, each fuel cell extending across the first major surface and positioned between the first end and the second end, wherein a first selected fuel cell of the plurality of fuel cells on the first major surface that is closest to the second end is laterally segmented such that a first lateral end of the first selected fuel cell is electrically isolated from a second lateral end of the first selected fuel cell; and

A third tube interconnect electrically connecting a first lateral end of a second selected fuel cell of the second fuel cell tube to a second lateral end of a first selected fuel cell of the third fuel cell tube.

4. The segmented serially solid oxide fuel cell system of claim 3, further comprising a fourth tube interconnect electrically connecting a second lateral end of a second selected fuel cell of the second fuel cell tubes to a first lateral end of a first selected fuel cell of the third fuel cell tubes.

5. The segmented serially solid oxide fuel cell system of claim 4, further comprising a second tube interconnect electrically connecting a second lateral end of a first selected fuel cell of the first fuel cell tube to a first lateral end of a first selected fuel cell of the second fuel cell tube.

6. The segmented series solid oxide fuel cell system of claim 5, further comprising a first primary interconnect electrically connecting a first selected fuel cell of the plurality of fuel cells of the first fuel cell tube to an interior selected fuel cell of the plurality of fuel cells of the first fuel cell tube, wherein a first lateral end of the first primary interconnect is electrically isolated from a second lateral end of the first primary interconnect.

7. The segmented series solid oxide fuel cell system of claim 6, further comprising a second primary interconnect electrically connecting a second selected fuel cell of the plurality of fuel cells of the second fuel cell tube to an interior selected fuel cell of the plurality of fuel cells of the second fuel cell tube, wherein a first lateral end of the second primary interconnect is electrically isolated from a second lateral end of the second primary interconnect.

8. A fuel cell tube comprising:

a substrate defining one or more fuel conduits therethrough, the substrate having a first end and an opposing second end, a first major surface extending between the first end and the second end, and an opposing second major surface extending between the first end and the second end; and

A plurality of fuel cells disposed on the first major surface, each fuel cell extending across the first major surface and positioned between the first end and the second end, wherein a first selected fuel cell of the plurality of fuel cells on the first major surface that is closest to the first end is laterally segmented such that a first lateral end of the first selected fuel cell is electrically isolated from a second lateral end of the first selected fuel cell; and is

Wherein a first interior selected fuel cell of the plurality of fuel cells disposed on the first major surface is a fuel cell adjacent to the first selected fuel cell;

Wherein the first inner selected fuel cell of the plurality of fuel cells is laterally segmented such that a first lateral end of the first inner selected fuel cell is electrically isolated from a second lateral end of the first inner selected fuel cell.

9. The fuel cell tube of claim 8, wherein a second selected fuel cell of the plurality of fuel cells on the first major surface that is closest to the second end is laterally segmented such that a first lateral end of the second selected fuel cell is electrically isolated from a second lateral end of the second selected fuel cell.

10. The fuel cell tube of claim 8, further comprising:

A plurality of fuel cells disposed on the second major surface, each fuel cell extending across the second major surface and positioned between the first end and the second end, wherein a first selected fuel cell of the plurality of fuel cells on the second major surface that is closest to the first end is laterally segmented such that a first lateral end of the first selected fuel cell on the second major surface is electrically isolated from a second lateral end of the first selected fuel cell on the second major surface; and is

Wherein a first interior selected fuel cell of the plurality of fuel cells disposed on the second major surface is a fuel cell adjacent the first selected fuel cell on the second major surface;

Wherein the first interior selected fuel cell of the plurality of fuel cells on the second major surface is laterally segmented such that a first lateral end of the first interior selected fuel cell on the second major surface is electrically isolated from a second lateral end of the first interior selected fuel cell on the second major surface.

11. the fuel cell tube of claim 10, wherein a second selected fuel cell of the plurality of fuel cells on the second major surface that is closest to the second end is laterally segmented such that a first lateral end of the second selected fuel cell on the second major surface is electrically isolated from a second lateral end of the second selected fuel cell on the second major surface.

12. The fuel cell tube of claim 11, further comprising a first fuel cell connector electrically connecting a first lateral end of a first selected fuel cell of the plurality of fuel cells on the first major surface to a first lateral end of a first selected fuel cell of the plurality of fuel cells on the second major surface.

13. The fuel cell tube of claim 12, further comprising a second fuel cell connector electrically connecting a second lateral end of a first selected fuel cell of the plurality of fuel cells on the first major surface to a second lateral end of a first selected fuel cell of the plurality of fuel cells on the second major surface.

14. The fuel cell tube of claim 13, further comprising a first primary interconnect electrically connecting a first selected fuel cell of the plurality of fuel cells on the first major surface to a first inner selected fuel cell of the plurality of fuel cells on the first major surface, wherein a first lateral end of the first primary interconnect is electrically isolated from a second lateral end of the first primary interconnect.

15. The fuel cell tube of claim 14, further comprising a second primary interconnect electrically connecting a first selected fuel cell of the plurality of fuel cells on the second major surface to a first inner selected fuel cell of the plurality of fuel cells on the second major surface, wherein a first lateral end of the second primary interconnect is electrically isolated from a second lateral end of the second primary interconnect.

Technical Field

The present disclosure relates to fuel cell tubes. More particularly, the present disclosure relates to a fuel cell tube comprising one or more laterally segmented fuel cells.

Background

A fuel cell is an electrochemical conversion device that produces electrical energy by oxidizing fuel. The fuel cell may be one of an electrochemically active fuel cell and an electrochemically inactive fuel cell (i.e., a mock cell). Electrochemically active fuel cells generally include an anode, a cathode, and an electrolyte disposed between the anode and the cathode. A fuel cell tube typically includes a plurality of fuel cells arranged on a substrate and electrically connected to each other in series via primary interconnects. A fuel cell stack typically includes a plurality of fuel cell tubes electrically connected in series with one another via a tube interconnect. A fuel cell system includes a plurality of fuel cell stacks electrically connected in series with each other and several components configured to provide fuel to an anode of the fuel cell and oxidant to a cathode of the fuel cell. Oxygen in the oxidant is reduced at the cathode to oxygen ions, which diffuse through the electrolyte layer into the anode. The fuel is oxidized at the anode, which releases electrons that flow through the electrical load.

Disclosure of Invention

Various embodiments of the present disclosure provide a fuel cell tube comprising one or more laterally segmented electrochemically active fuel cells or mock cells, each cell comprising lateral electrochemically active fuel cell or mock cell portions electrically isolated from each other such that there is no continuous electrical pathway across the width of the tube. When assembled into a fuel cell stack, the tube interconnects are electrically connected to adjacent fuel cell tubes via their respective laterally segmented fuel cells. The use of laterally segmented electrochemically active fuel cells or mock cells to create fuel cell tube-to-fuel cell tube electrical connections enables more accurate testing of electrical connections between adjacent fuel cell tubes.

In some examples, a segmented-in-series (segmented-in-series) solid oxide fuel cell system includes a first fuel cell tube, a second fuel cell tube, and a first tube interconnect. The first fuel cell tube can include a substrate having a first end and an opposing second end, a first major surface extending between the first and second ends, and a second opposing major surface extending between the first and second ends. The first fuel cell tube may also include a plurality of fuel cells disposed on the first major surface, each fuel cell extending laterally across the first major surface and positioned between the first and second ends. In some examples, a first selected fuel cell of the plurality of fuel cells on the first major surface that is closest to the first end is laterally segmented such that the first lateral end of the first selected fuel cell is electrically isolated from the second lateral end of the first selected fuel cell. In some examples, the fuel cell tube may comprise a "mock" cell, i.e., a cell comprising only a cathode layer or a cathode layer and a cathode current collector layer. In some examples, the internal selected fuel cell of the plurality of fuel cells is a fuel cell adjacent to the first selected fuel cell. The internally selected fuel cell of the plurality of fuel cells may be laterally segmented such that a first lateral end of the internally selected fuel cell is electrically isolated from a second lateral end of the internally selected fuel cell.

the second fuel cell tube can include a substrate having a first end and an opposing second end, a first major surface extending between the first and second ends, and a second opposing major surface extending between the first and second ends. The second fuel cell tube may also include a plurality of fuel cells disposed on the first major surface, each fuel cell extending laterally across the first major surface and positioned between the first and second ends. In some examples, a first selected fuel cell of the plurality of fuel cells on the first major surface that is closest to the second end is laterally segmented such that the first lateral end of the first selected fuel cell is electrically isolated from the second lateral end of the first selected fuel cell. In some examples, the fuel cell tube may comprise a "mock" cell, i.e., a cell comprising only a cathode layer or a cathode layer and a cathode current collector layer.

The segmented series solid oxide fuel cell system can further include a first tube interconnect electrically connecting a first lateral end of a first selected fuel cell of the first fuel cell tube to a second lateral end of a first selected fuel cell of the second fuel cell tube.

In some examples, a fuel cell tube includes a substrate defining one or more fuel conduits therethrough, the substrate having a first end and an opposing second end, a first major surface extending between the first and second ends, and a second opposing major surface extending between the first and second ends. The fuel cell tube may also include a plurality of fuel cells disposed on the first major surface, each fuel cell extending laterally across the first major surface and positioned between the first and second ends. In some examples, a first selected fuel cell of the plurality of fuel cells on the first major surface that is closest to the first end is laterally segmented such that the first lateral end of the first selected fuel cell is electrically isolated from the second lateral end of the first selected fuel cell. In some examples, the first interior selected fuel cell of the plurality of fuel cells disposed on the first major surface is a fuel cell adjacent to the first selected fuel cell. A first interior selected fuel cell of the plurality of fuel cells may be laterally segmented such that a first lateral end of the first interior selected fuel cell is electrically isolated from a second lateral end of the first interior selected fuel cell.

Drawings

Fig. 1 is a top view of one embodiment of a fuel cell tube of the present disclosure.

Fig. 2 is a side view of the fuel cell tube of fig. 1.

Fig. 3 is a front cross-sectional view of the fuel cell tube of fig. 1 taken substantially along line 3-3 of fig. 1.

Fig. 4 is a side cross-sectional view of a portion of one of the fuel cells of the fuel cell tube of fig. 1, taken substantially along line 4-4 of fig. 1.

Figure 5 is a side view of six fuel cell tubes of one embodiment of a fuel cell stack of the present disclosure.

Figure 6 is a front cross-sectional view of the fuel cell tubes of the fuel cell stack of figure 5 taken substantially along line 6-6 of figure 5.

Figure 7 is a rear cross-sectional view of the fuel cell tubes of the fuel cell stack of figure 5 taken substantially along the line 7-7 of figure 5.

Figures 8A-8D are front cross-sectional views of two prior art fuel cell tubes of a prior art fuel cell stack during a resistance test.

Figures 9A-9D are front cross-sectional views of two fuel cell tubes of the fuel cell stack of figure 5 during a resistance test, taken substantially along line 6-6 of figure 5.

Fig. 10A and 10B are schematic diagrams showing side views of one embodiment of a fuel cell tube of the present disclosure along the length direction of the tube. Fig. 10A shows the anode side of the tube and fig. 10B shows the cathode side of the tube.

Fig. 11A and 11B are schematic diagrams showing a top view of one embodiment of a fuel cell tube of the present disclosure. Fig. 11C and 11D are schematic diagrams showing a bottom view of one embodiment of a fuel cell tube of the present disclosure. Fig. 11A and 11C show the anode side of the tube, and fig. 11B and 11D show the cathode side of the tube.

Fig. 12 is a top view of an embodiment of a fuel cell tube of the present disclosure.

Fig. 13 is a side view of the fuel cell tube of fig. 12.

Fig. 14A is a front cross-sectional view of the fuel cell tube of fig. 12 taken substantially along line 8-8 of fig. 12. Fig. 14B is a front cross-sectional view of the fuel cell tube of fig. 12 taken substantially along line 9-9 of fig. 12.

Fig. 15A and 15B are front cross-sectional views of three fuel cell tubes of an embodiment of a fuel cell stack of the present disclosure.

Detailed Description

While the features, methods, devices, and systems described herein can be implemented in various ways, the figures show and describe in detail some exemplary and non-limiting embodiments. Not all of the components shown and described in the figures and detailed description are required, and some implementations may include additional, different, or fewer components than those shown and described. The arrangement and type of components may be varied without departing from the spirit and scope of the claims presented herein; the shape, size and material of the component; and the manner in which the components are attached and connected. This description is to be taken in an entirety and is to be construed in accordance with the principles of the present invention as taught herein and understood by those of ordinary skill in the art.

Fig. 1-4 illustrate one exemplary embodiment of a fuel cell tube 100 and its components of the present disclosure. Fig. 5-7 illustrate a portion of an exemplary embodiment of a fuel cell stack 10 of the present disclosure that includes a fuel cell tube 100 and fuel cell tubes 200, 300, 400, 500, and 600 electrically connected to one another.

The fuel cell tube 100 includes a porous substrate 110 having a width W, a length L, a thickness T, a substantially planar upper major surface 110a, and a substantially planar lower major surface 110 b. As shown in fig. 3, a plurality of fuel conduits 110c extend through the substrate 110 along the length L of the substrate 110. The fuel cell tubes 100 can be fluidly connected to a manifold (not shown) that can be fluidly connected to a fuel source such that fuel can flow from the fuel source, through the manifold and into and through the fuel conduit 110 c. In the exemplary embodiment, substrate 110 is made of MgO — MgAl₂O₄(MMA) although in other embodiments, the substrate 110 may be formed from any suitable material (e.g., doped zirconia and/or forsterite) in addition to or in place of MMA.

First and second porous anode barrier layers 120a and 120b are disposed on the upper and lower major surfaces 110a and 110b of the substrate 110, respectively. The first and second porous anode barriers 120a and 120b are configured to prevent reactions between the anode of the fuel cell (described below) and the substrate 110, and are not configured to provide electrical conductivity within a given fuel cell or between two fuel cells. In addition, the first and second porous anode barriers 120a and 120b are not configured to participate in an electrochemical reaction that generates electrical energy from the fuel. In the exemplary embodiment, first and second porous anode barriers 120a and 120b are formed from an inert porous ceramic material that is not an electrical conductor, such as 3YSZ or another suitable doped zirconia, although in other embodiments, first and second porous anode barriers 120a and 120b may be formed from any suitable material (e.g., SrZrO) in addition to or in place of doped zirconia₃or SrTiO₃Doped zirconia composite). In other embodiments, the fuel cell tube 100 does not include the first and second porous anode barriers 120a and 120 b.

A plurality of fuel cells 130, a first laterally segmented fuel cell 140, and a second laterally segmented fuel cell 150 are disposed on the first porous anode barrier 120 a. Each fuel cell 130, first laterally segmented fuel cell 140, and second laterally segmented fuel cell 150 extends laterally generally in the width W direction of the substrate 110 and terminates in opposing first and second lateral ends (not labeled). The fuel cell 130 is positioned between first and second laterally segmented fuel cells 140 and 150, the first and second laterally segmented fuel cells 140 and 150 being positioned at opposite ends of the first porous anode barrier layer 120a generally along the length L of the substrate 110. The fuel cell 130, the first laterally segmented fuel cell 140, and the second laterally segmented fuel cell 150 on the first porous anode barrier 120a are electrically connected in series via a primary interconnect (not shown).

As best shown in fig. 1 and 3, the first laterally segmented fuel cell 140 includes first and second fuel cell portions 140a and 140 b. The first and second fuel cell portions 140a and 140b are laterally separated by a spacing 140c along the width W of the substrate 110 such that the first and second fuel cell portions 140a and 140b are electrically isolated such that there is no continuous electrical path across the width of the fuel cell tube in the fuel cell. In other words, there is no continuous direct electrical path between the first and second fuel cell portions 140a and 140b along the width W of the substrate 110. In the exemplary embodiment, spacing 140c is 0.5 millimeters in the width W direction of substrate 110, although spacing 140c can be any suitable dimension sufficient to ensure that first and second fuel cell portions 140a and 140b are electrically isolated.

As best shown in fig. 1 and 3, the second laterally segmented fuel cell 150 includes first and second fuel cell portions 150a and 150 b. The first and second fuel cell portions 150a and 150b are laterally separated by a spacing 150c along the width W of the substrate 110 such that the first and second fuel cell portions 150a and 150b are electrically isolated such that there is no continuous electrical path across the width of the fuel cell tube in the fuel cell. In other words, there is no continuous direct electrical path between the first and second fuel cell portions 150a and 150b along the width W of the substrate 110. In the exemplary embodiment, spacing 150c is 0.5 millimeters in the width W direction of substrate 110, although spacing 150c may be any suitable dimension sufficient to ensure that first and second fuel cell portions 150a and 150b are electrically isolated.

Similarly, a plurality of fuel cells 130, a third laterally segmented fuel cell 160, and a fourth laterally segmented fuel cell 170 are disposed on the second porous anode barrier 120 b. Each of the fuel cells 130, the third laterally segmented fuel cell 160, and the fourth laterally segmented fuel cell 170 extends laterally substantially in the direction of the width W of the substrate 110. The fuel cell 130 is positioned between third and fourth laterally segmented fuel cells 160 and 170, the third and fourth laterally segmented fuel cells 160 and 170 being positioned at opposite ends of the second porous anode barrier 120b generally along the length L of the substrate 110. The fuel cell 130, the third laterally segmented fuel cell 160, and the fourth laterally segmented fuel cell 170 on the second porous anode barrier 120b are electrically connected in series via a primary interconnect (not shown).

As best shown in fig. 1 and 3, the third laterally segmented fuel cell 160 includes first and second fuel cell portions 160a and 160 b. The first and second fuel cell portions 160a and 160b are separated by a spacing 160c along the width W of the substrate 110 such that the first and second fuel cell portions 160a and 160b are electrically isolated such that there is no continuous electrical path across the width of the fuel cell tube in the fuel cell. In other words, there is no continuous direct electrical path between the first and second fuel cell portions 160a and 160b along the width W of the substrate 110. In the exemplary embodiment, spacing 160c is 0.5 millimeters in the width W direction of substrate 110, although spacing 160c may be any suitable dimension sufficient to ensure that first and second fuel cell portions 160a and 160b are electrically isolated.

As best shown in fig. 1 and 3, the fourth laterally segmented fuel cell 170 includes first and second fuel cell portions 170a and 170 b. The first and second fuel cell portions 170a and 170b are laterally separated by a spacing 170c in the width W direction of the substrate 110 such that the first and second fuel cell portions 170a and 170b are electrically isolated such that there is no continuous electrical path across the width of the fuel cell tube in the fuel cell. In other words, there is no continuous direct electrical path between the first and second fuel cell portions 170a and 170b along the width W of the substrate 110. In the exemplary embodiment, spacing 170c is 0.5 millimeters in the width W direction of substrate 110, although spacing 170c may be any suitable dimension sufficient to ensure that first and second fuel cell portions 170a and 170b are electrically isolated.

as shown in fig. 4, each fuel cell 130 and each fuel cell portion of each laterally segmented fuel cell 140, 150, 160, 170, 181, 190, and 191 includes an anode current collector 130a, an anode 130b, an electrolyte 130c, a cathode 130d, and a cathode current collector 130 e. The anode 130b is disposed between the anode current collector 130a and the electrolyte 130 c. The electrolyte 130c is disposed between the anode 130b and the cathode 130 d. The cathode 130d is disposed between the electrolyte 130c and the cathode current collector 130 e. The anode current collector 130a is electrically connected to the anode 130b, and the cathode current collector 130e is electrically connected to the cathode 130 d. The anode and cathode current collectors 130a and 130e provide a higher conductive path for the migration of electrons than the anode and cathode together may provide.

In this exemplary embodiment, the anode current collector 130a is an electrode conductive layer formed of a nickel cermet. Examples of suitable materials include Ni-YSZ (yttria doped in zirconia at 3-8 mol%); Ni-ScSZ (scandium oxide doping 4-10 mol%, preferably the second doping for 10 mol% scandium oxide-ZrO₂Phase stabilization of (a); ni-doped ceria (e.g. Gd or Sm doped); ni and doped lanthanum chromate cermets (e.g., Ca doping at a sites and Zn doping at B sites); cermet of Ni and doped strontium titanate (e.g. La doping at A site and Mn doping at B site) and/or La_{1- x}Sr_xMn_yCr_1-yO₃. In other embodimentsIn an aspect, the anode current collector may be formed of a cermet based at least in part on one or more noble metals and/or one or more noble metal alloys in addition to maintaining the Ni content. The noble metal in the cermet may include, for example, Pt, Pd, Au, Ag, and/or alloys thereof. The ceramic phase may include, for example, an inactive non-conductive phase including, for example, YSZ, ScSZ, and/or one or more other inactive phases, for example, having a desired Coefficient of Thermal Expansion (CTE) to control the CTE of the layer to match the CTE of the substrate 110 and electrolyte 130 c. In some embodiments, the ceramic phase may include Al₂O₃And/or spinel such as NiAl₂O₄、MgAl₂O₄、MgCr₂O₄Or NiCr₂O₄. In other embodiments, the ceramic phase may be electrically conductive, such as doped lanthanum chromate, doped strontium titanate, and/or one or more forms of LaSrMnCrO. One specific example of a material for anode current collector 130a is 76.5% Pd, 8.5% Ni, 15% 3 YSZ.

In this exemplary embodiment, anode 130b is formed from xNiO- (100-x) YSZ (x from 55 to 75 weight percent), yNiO- (100-y) ScSZ (y from 55 to 75 weight percent), NiO-gadolinia stabilized ceria (e.g., 55 wt% NiO-45 wt% GDC), and/or NiO samaria stabilized ceria. In other embodiments, the anode may be made of doped strontium titanate, La_1-xSr_xMn_yCr_1-yO₃(e.g., La)_0.75Sr_0.25Mn_0.5Cr_0.5O₃) And/or other ceramic-based anode materials.

In the exemplary embodiment, electrolyte 130c is formed of a ceramic material. In some embodiments, electrolyte 130c is formed of a proton and/or cation conducting ceramic. In other embodiments, electrolyte 130c is formed from YSZ, such as 3YSZ and/or 8 YSZ. In other embodiments, the electrolyte 130c is formed of ScSZ, such as 4ScSZ, 6ScSZ, and/or 10ScSZ, in addition to or in place of YSZ. In other embodiments, the electrolyte 130c may be formed of doped ceria and/or doped lanthanum gallate. Electrolyte 130c substantially does not allow electricity to pass through or past the fuelOxidant (e.g. air or O) flowing through cell tube 100₂) And fuel (e.g. H)₂) Through which diffusion of oxygen ions and/or protons is permitted, depending on the particular embodiment and its application.

In this exemplary embodiment, cathode 130d is formed from a mixture of an electrochemically catalytic ceramic and an ionic phase. The electrochemical catalytic phase is composed of LSM (La)_1-xSr_xMnO₃x ═ 0.1 to 0.3), La_1-xSr_xFeO₃(e.g., x ═ 0.3), La_1-xSr_xCo_yFe_{1- y}O₃(e.g., La)_0.6Sr_0.4Co_0.2Fe_0.8O₃) And/or Pr_1-xSr_xMnO₃(e.g., Pr)_0.8Sr_0.2MnO₃) Although other materials may be used. For example, in some embodiments, cathode 130d is formed from Ruddlesden-Popper nickelate and La_1-xCa_xMnO₃(e.g., La)_0.8Ca_0.2MnO₃) The material is formed. The ionic phase may be YSZ, which contains 3-8 mole% yttria; or ScSZ containing 4-10 mole% scandia and optionally a low content (about 1 mole%) of a second dopant of Al, Y or ceria for high scandia stabilized zirconia (8-10 ScSZ) to prevent the formation of the rhombohedral phase. The electrochemically catalytic ceramic phase may comprise 40-60% of the volume of the cathode.

In this exemplary embodiment, the cathode current collector 130e is an electrode conductive layer formed of a conductive ceramic and is in many cases similar in its chemistry to the electrochemically catalytic ceramic phase of the cathode. For example, a LSM + YSZ cathode will typically employ LSM (La)_1-xSr_xMnO₃and x ═ 0.1 to 0.3) a cathode current collector. Other embodiments of the cathode current collector 130e may include LaNi_xFe_1-xO₃(e.g., LaNi)_0.6Fe_0.4O₃)、La_1-xSr_xMnO₃(e.g., La)_0.75Sr_0.25MnO₃) Doped lanthanum chromite (e.g. La)_1-xCa_xCrO_3-δX is 0.15-0.3) and/or Pr_1-xSr_xCoO₃Such as Pr_0.8Sr_0.2CoO₃At least one of (1). In other embodiments, the cathode current collector 130e may be formed of a noble metal cermet. The noble metal in the noble metal cermet may include, for example, Pt, Pd, Au, Ag, and/or alloys thereof. May also include non-conductive ceramic phases, e.g., YSZ, ScSZ, and Al₂O₃Or other ceramic material. One specific example of a material for the cathode current collector 130e is 80 wt% Pd-20 wt% LSM.

In this exemplary embodiment, fuel cell 130 and laterally segmented fuel cells 140, 150, 160, 170, 181, 190, and 191 are formed by: films/layers are deposited on the upper and lower major surfaces 110a and 110b of the substrate 110 by, for example, screen printing and/or ink jet printing to form a porous anode barrier layer, a primary interconnect, an anode current collector and anode, an electrolyte, and a cathode and cathode current collector. In other embodiments, the film/layer may be deposited by one or more other techniques in addition to or instead of screen printing and/or inkjet printing. In various embodiments, one or more firing/sintering cycles are performed after deposition of one or more films/layers. Other embodiments may not require any firing/sintering for one or more film/layer depositions.

The first fuel cell connector 145a is electrically connected to (and electrically connects) the first fuel cell portion 140a of the first laterally segmented fuel cell 140 and the first fuel cell portion 160a of the third laterally segmented fuel cell 160. The second fuel cell connector 145b is electrically connected to (and electrically connects) the second fuel cell portion 140b of the first laterally segmented fuel cell 140 and the second fuel cell portion 160b of the third laterally segmented fuel cell 160. The third fuel cell connector 155a is electrically connected to (and electrically connects) the first fuel cell portion 150a of the second laterally segmented fuel cell 150 and the first fuel cell portion 170a of the fourth laterally segmented fuel cell 170. The fourth fuel cell connector 155b is electrically connected to (and electrically connects) the second fuel cell portion 150b of the second laterally segmented fuel cell 150 and the second fuel cell portion 170b of the fourth laterally segmented fuel cell 170.

in this exemplary embodiment, first fuel cell connector 145a is electrically connected to (and in this exemplary embodiment contacts) the cathode current collectors of first fuel cell portions 140a and 160a, and second fuel cell connector 145b is electrically connected to (and in this exemplary embodiment contacts) the cathode current collectors of second fuel cell portions 140b and 160 b. Since first and second fuel cell portions 140a and 140b are electrically isolated and first and second fuel cell portions 160a and 160b are electrically isolated, first and second fuel cell connectors 145a and 145b are electrically isolated such that there is no continuous electrical path across the width W of the tube (substrate 110).

In this exemplary embodiment, third fuel cell connector 155a is electrically connected to (and in this exemplary embodiment is in contact with) the cathode current collectors of first fuel cell portions 150a and 170a, and fourth fuel cell connector 155b is electrically connected to (and in this exemplary embodiment is in contact with) the cathode current collectors of second fuel cell portions 150b and 170 b. Since the first and second fuel cell portions 150a and 150b are electrically isolated and the first and second fuel cell portions 170a and 170b are electrically isolated, the third and fourth fuel cell connectors 155a and 155b are electrically isolated such that there is no continuous electrical path across the width W of the tube (substrate 110).

Fig. 5-7 show six fuel cell tubes 100, 200, 300, 400, 500, and 600 of the fuel cell stack 10. Although the fuel cell stack 10 may include any suitable number of fuel cell tubes electrically connected to one another in series, only six are shown here for clarity and brevity. In this exemplary embodiment, the fuel cell tubes 200, 300, 400, 500, and 600 are identical to the fuel cell tube 100 and therefore are not described separately (although in other embodiments the fuel cell tubes may be different from one another). The numbering scheme of the elements of fuel cell tubes 200, 300, 400, 500, and 600 corresponds to the numbering scheme used to describe fuel cell tube 100, such that like element numbers correspond to like components.

The first fuel cell tube 100 is electrically connected to the second fuel cell tube 200 via: (1) a first tube interconnect 12a electrically connecting the third fuel cell connector 155a of the first fuel cell tube 100 to the third fuel cell connector 255a of the second fuel cell tube 200; and (2) a second tube interconnect 12b electrically connecting the fourth fuel cell connector 155b of the first fuel cell tube 100 to the fourth fuel cell connector 255b of the second fuel cell tube 200. Typically, the fuel cell tubes are connected in series along the direction of fuel flow through the tubes.

The second fuel cell tube 200 is electrically connected to the third fuel cell tube 300 via: (1) a third tube interconnect 23a electrically connecting the first fuel cell connector 245a of the second fuel cell tube 200 to the first fuel cell connector 345a of the third fuel cell tube 300; and (2) a fourth tube interconnect 23b electrically connecting the second fuel cell connector 245b of the second fuel cell tube 200 to the second fuel cell connector 345b of the third fuel cell tube 300.

The third fuel cell tube 300 is electrically connected to the fourth fuel cell tube 400 via: (1) a fifth tube interconnect 34a electrically connecting the third fuel cell connector 355a of the third fuel cell tube 300 to the third fuel cell connector 455a of the fourth fuel cell tube 400; and (2) a sixth tube interconnect 34b electrically connecting the fourth fuel cell connector 355b of the third fuel cell tube 300 to the fourth fuel cell connector 455b of the fourth fuel cell tube 400.

The fourth fuel cell tube 400 is electrically connected to the fifth fuel cell tube 500 via: (1) a seventh tube interconnect 45a electrically connecting the first fuel cell connector 445a of the fourth fuel cell tube 400 to the first fuel cell connector 545a of the fifth fuel cell tube 500; and (2) eighth tube interconnect 45b electrically connecting second fuel cell connector 445b of fourth fuel cell tube 400 to second fuel cell connector 545b of fifth fuel cell tube 500.

The fifth fuel cell tube 500 is electrically connected to the sixth fuel cell tube 600 via: (1) a ninth tube interconnect 56a electrically connecting the third fuel cell connector 555a of the fifth fuel cell tube 500 to the third fuel cell connector 655a of the sixth fuel cell tube 600; and (2) a tenth tube interconnect 56b that electrically connects the fourth fuel cell connector 555b of the fifth fuel cell tube 500 to the fourth fuel cell connector 655b of the sixth fuel cell tube 600.

Although not shown here, the first fuel cell tube 100 may be electrically connected to another fuel cell tube of the fuel cell stack 10 or to another fuel cell stack via a tube interconnect shown in fig. 5 and 7 but not labeled. Similarly, the sixth fuel cell tube 600 may be electrically connected to another fuel cell tube of the fuel cell stack 10 or to another fuel cell stack via tube interconnects shown in fig. 5 and 7 but not labeled.

In operation, as oxidant flows through the cathode of the fuel cell tube and as fuel flows through the fuel conduit of the base of the fuel cell tube, the electrochemical reactions occurring at the cathode and anode produce free electrons at the anode. Within a particular fuel cell tube, those free electrons flow as current in a particular direction from one fuel cell to the next (via the anode current collector, the primary interconnect, and the cathode current collector). Once the current reaches the last fuel cell of the fuel cell tube (here the laterally segmented fuel cell), the current flows to the next fuel cell tube via the fuel cell connectors and the tube interconnect, and so on, until the electrical load is reached.

For example, as shown in fig. 5, in this exemplary embodiment, the current I flows as follows: (1) from the laterally segmented fuel cells 140 and 160, through the fuel cell 130 and to the laterally segmented fuel cells 150 and 170 within the fuel cell tube 100; (2) from the laterally segmented fuel cells 150 and 170 of the fuel cell tube 100 to the laterally segmented fuel cells 250 and 270 of the fuel cell tube 200 via the fuel cell connectors 155a, 155b, 255a and 255b and the tube interconnects 12a and 12 b; (3) from laterally segmented fuel cells 250 and 270 through fuel cell 230 and to laterally segmented fuel cells 240 and 260 within fuel cell tube 200; (4) from the laterally segmented fuel cells 240 and 260 of the fuel cell tube 200, to the fuel cells 340 and 360 of the fuel cell tube 300 via fuel cell connectors 245a, 245b, 345a and 345b and tube interconnects 23a and 23 b; (5) from laterally segmented fuel cells 340 and 360 through fuel cell 330 and to laterally segmented fuel cells 350 and 370 within fuel cell tube 300; (6) from the laterally segmented fuel cells 350 and 370 of the fuel cell tube 300 to the laterally segmented fuel cells 450 and 470 of the fuel cell tube 400 via the fuel cell connectors 355a, 355b, 455a and 455b and the tube interconnects 34a and 34 b; (7) within the fuel cell tube 400 from the electrically isolated fuel cells 450 and 470 through the fuel cell 430 and to the laterally segmented fuel cells 440 and 460; (8) from the laterally segmented fuel cells 440 and 460 of fuel cell tube 400 to the laterally segmented fuel cells 540 and 560 of fuel cell tube 500 via fuel cell connectors 445a, 445b, 545a and 545b and tube interconnects 45a and 45 b; (9) from the laterally segmented fuel cells 540 and 560 through the fuel cell 530 and to the laterally segmented fuel cells 550 and 570 within the fuel cell tube 500; (10) from the laterally segmented fuel cells 550 and 570 of fuel cell tube 500 to the laterally segmented fuel cells 650 and 670 of fuel cell tube 600 via fuel cell connectors 555a, 555b, 655a and 655b and tube interconnects 56a and 56 b; (11) from laterally segmented fuel cells 650 and 670 through fuel cell 630 and to laterally segmented fuel cells 640 and 660 within fuel cell tube 600; and (12) from the laterally segmented fuel cells 640 and 660 of fuel cell tube 600 to an electrical load (or to another fuel cell tube or fuel cell stack) via fuel cell connectors 645a and 645 b.

In order for a fuel cell stack to conduct current from one fuel cell tube to another, the tube interconnect must be operational, i.e., provide a path for current to flow from one fuel cell tube to another. One way to check whether a given tube interconnect is operational is by using an ohmmeter to attempt to flow current through the tube interconnect and calculate the resistance across the tube interconnect. If the resistance is relatively low (e.g., negligible), current can flow through the tube interconnect. However, if the resistance is relatively high (e.g., infinite), current cannot flow through the tube interconnects, and the tube interconnects are damaged and must be repaired or replaced to ensure proper fuel cell stack operation.

Since the prior art fuel cell tubes do not include laterally segmented fuel cells, their fuel cell connectors are electrically connected to laterally continuous fuel cells. As described below, this results in the ohmmeter in some cases producing false positive readings (false positive readings) when calculating the resistance across a particular tube interconnect. That is, in some cases, when a tube interconnect is actually damaged such that current flows therethrough, the ohmmeter calculates a relatively low resistance across the given tube interconnect — and thus indicates an operational tube interconnect.

Fig. 8A-8D show a negative ohmmeter probe N and a positive ohmmeter probe P positioned to attempt to flow an electrical current I through a tube interconnect 1012b that electrically connects the prior art fuel cell tubes 1100 and 1200. The opposing tube interconnects 1012a also electrically connect the prior art fuel cells 1100 and 1200. The fuel cell connectors (not labeled) of the fuel cell tubes 1100 and 1200 are electrically connected to laterally consecutive fuel cells.

In the case shown in FIG. 8A, both of the pipe interconnects 1012a and 1012b are operational. The ohmmeter calculates a low resistance because the tube interconnect 1012b is active and a current I can flow from the negative probe N to the positive probe P through the tube interconnect 1012 b.

in the case shown in fig. 8B, the tube interconnect 1012a is in an operating state, and the tube interconnect 1012B is damaged so that current cannot flow therethrough. However, the ohmmeter does not calculate a high resistance corresponding to the inability of current to flow through the plumbing interconnects 1012b, but rather a low resistance because current flows from the negative probe N through the laterally continuous fuel cells of the fuel cell tube 1100, through the plumbing interconnects 1012a, and through the laterally continuous fuel cells of the fuel cell tube 1200 to the positive probe P. In other words, the laterally continuous fuel cell current I flowing from the negative probe N to the positive probe P provides a low resistance path, so the current does so and causes the ohmmeter to calculate a low resistance that does not reflect the damaged state of the plumbing interconnect 1012 b.

In the case shown in fig. 8C, the tube interconnect 1012a is damaged such that current cannot flow therethrough, while the tube interconnect 1012b is in an operating state. The ohmmeter calculates a low resistance because the pipe interconnect 1012b is active and a current I can flow from the negative probe N to the positive probe P through the pipe interconnect 1012 b.

In the case shown in fig. 8D, the tube interconnects 1012a and 1012b are damaged such that current cannot flow therethrough. The ohmmeter calculates a high resistance because current cannot flow from the negative probe N to the positive probe P through either of the plumbing interconnects 1012a or 1012 b.

The fuel cell tube with laterally segmented fuel cells of the present disclosure addresses this problem. As explained above, the fuel cell connectors of the fuel cell tubes of the present disclosure are electrically connected to the laterally segmented fuel cells, which means that there is only one low resistance electrical path when attempting to flow current through the tube interconnects in a resistance test.

Fig. 9A-9D show the negative probe N and the positive probe P of the ohmmeter described above positioned to attempt to flow current through the plumbing interconnect 12 b.

In the situation shown in fig. 9A, the pipe interconnections 12a and 12b are both active. The ohmmeter calculates a low resistance because the pipe interconnect 12b is active and a current I can flow from the negative probe N to the positive probe P through the pipe interconnect 12 b.

In the case shown in fig. 9B, the tube interconnect 12a is in an operating state, and the tube interconnect 12B is damaged, so that current cannot flow therethrough. The ohmmeter calculates a high resistance because current cannot flow from the negative probe N to the positive probe P through the pipe interconnect 12 b. Furthermore, current cannot flow from the negative probe N to the positive probe P through the tube interconnect 12a because there is no low resistance electrical path between the negative probe N and the positive probe P through the tube interconnect 12a due to the laterally segmented fuel cell.

In the case shown in fig. 9C, the tube interconnect 12a is damaged so that current cannot flow therethrough, while the tube interconnect 12b is in an operating state. The ohmmeter calculates a low resistance because the pipe interconnect 12b is active and a current I can flow from the negative probe N to the positive probe P through the pipe interconnect 12 b.

In the case shown in fig. 9D, the tube interconnections 12a and 12b are damaged so that current cannot flow therethrough. The ohmmeter calculates a high resistance because current cannot flow from the negative probe N to the positive probe P through either of the plumbing interconnects 12a or 12 b.

Another benefit is that the use of laterally segmented fuel cells has a negligible effect on the performance of a given fuel cell tube because of the low current density at the spaces between fuel cell sections because the current is concentrated at the fuel cell connectors through which the current flows to the next fuel cell tube.

Fig. 10A and 10B are schematic diagrams showing a side view of a fuel cell tube 2100 along the length of the tube. Figure 10A shows a schematic of the anode side of a fuel cell tube including a tube interconnect connection region at a laterally segmented analog cell portion 2180 b. The laterally segmented simulated cell portion 2180b includes a cathode current collector 2130e and a cathode 2130 d. The laterally segmented analog cell portion 2180b is electrically connected to the laterally segmented fuel cell portion 2181b via primary interconnects within a primary interconnect region 2111, which primary interconnect region 2111 may be covered with a dense barrier layer 2120 c. Dense barrier layer 2120c may be formed of yttria stabilized zirconia (preferably 3 YSZ). The dense barrier 2120c may also be formed of 8YSZ or ScSz and may have additional impurities that recombine to reduce its ionic conductivity. The dense barrier layer 2120c may also be formed of a non-zirconia ceramic that does not have electrical conductivity. The lateral segments extend into the primary interconnect region 2111 connected to the analog cell 2180 and into the fuel cell 2181 to allow electrical isolation of the fuel cell in operation.

The laterally segmented fuel cell portion 2181b includes a cathode current collector 2130e, a cathode 2130d, an electrolyte 2130c, an anode 2130b and an anode current collector 2130 a. Anode 2130b is disposed between anode current collector 2130a and electrolyte 2130 c. Electrolyte 2130c is disposed between anode 2130b and cathode 2130 d. Cathode 2130d is disposed between electrolyte 2130c and cathode current collector 2130 e. Anode current collector 2130a is electrically connected to anode 2130b, and cathode current collector 2130e is electrically connected to cathode 2130 d. Anode current collector 2130a and cathode current collector 2130e provide a higher conductive path for the migration of electrons than would be possible with the anode and cathode alone. The laterally segmented fuel cell portion 2181b is electrically connected to the fuel cell 2130 through primary interconnects within a primary interconnect region 2111, which primary interconnect region 2111 may be covered with a dense barrier layer 2120 c. Dense barrier layer 2120c may be formed of yttria stabilized zirconia (preferably 3 YSZ). The dense barrier 2120c may also be formed of 8YSZ or ScSz and may have additional impurities that recombine to reduce its ionic conductivity. The dense barrier layer 2120c may also be formed of a non-zirconia ceramic that does not have electrical conductivity.

The fuel cell 2130 may be further electrically connected to other fuel cells 2130 by primary interconnects within the primary interconnect region 2111. The porous anode barrier 2120a may be printed onto the upper major surface 2110a (not shown) of the tube 2100 and covered by the laterally segmented simulated cell portion 2180b, the laterally segmented fuel cell portion 2181b, the fuel cell 2130, the primary interconnect region 2111, and the optional dense barrier 2120 c. Fuel passes through the porous anode barrier 2120a to the active cell.

in fuel cell 2130 and laterally segmented fuel cell portion 2181b, anode 2130b is disposed between anode current collector 2130a and electrolyte 2130 c. Electrolyte 2130c is disposed between anode 2130b and cathode 2130 d. Cathode 2130d is disposed between electrolyte 2130c and cathode current collector 2130 e. Anode current collector 2130a is electrically connected to anode 2130b, and cathode current collector 2130e is electrically connected to cathode 2130 d. Anode current collector 2130a and cathode current collector 2130e provide a higher conductive path for the migration of electrons than would be possible with the anode and cathode alone.

Fig. 10B shows a schematic of the cathode side of the fuel cell tube 2100, including the tube interconnect connection region at the laterally segmented fuel cell portion 2190B. The laterally segmented fuel cell portion 2190b includes a cathode current collector 2130e, a cathode 2130d, an electrolyte 2130c, an anode 2130b, and an anode current collector 2130a, wherein the cathode current collector 2130e, the cathode 2130d, and the electrolyte 2130c extend past the anode 2130b and the anode current collector 2130a into the tube interconnect connection region. Anode 2130b is disposed between anode current collector 2130a and electrolyte 2130 c. Electrolyte 2130c is disposed between anode 2130b and cathode 2130 d. Cathode 2130d is disposed between electrolyte 2130c and cathode current collector 2130 e. Anode current collector 2130a is electrically connected to anode 2130b, and cathode current collector 2130e is electrically connected to cathode 2130 d. Anode current collector 2130a and cathode current collector 2130e provide a higher conductive path for the migration of electrons than would be possible with the anode and cathode alone. The laterally segmented fuel cell portion 2190b may be further electrically connected to the fuel cell 2130 via primary interconnects within the primary interconnect region 2111, which primary interconnect region 2111 may be covered with a dense barrier layer 2120 c. Dense barrier layer 2120c may be formed of yttria stabilized zirconia (preferably 3 YSZ). The dense barrier 2120c may also be formed of 8YSZ or ScSz and may have additional impurities that recombine to reduce its ionic conductivity.

The fuel cell 2130 may be further electrically connected to other fuel cells 2130 by primary interconnects within a primary interconnect region 2111, which primary interconnect region 2111 may be covered with a dense barrier layer 2120 c. The porous anode barrier layer 2120a is printed onto the upper major surface 2110a (not shown) of the tube 2100 and covered by the laterally segmented fuel cell portion 2190b, the fuel cell 2130, the primary interconnect region 2111, and the optional dense barrier layer 2120 c. Fuel passes through the porous anode barrier 2120a to the active cell.

In this exemplary embodiment, anode current collector 2130a is an electrode conductive layer formed of a nickel cermet. Examples of suitable materials include Ni-YSZ (yttria doped in zirconia at 3-8 mol%); Ni-ScSZ (scandium oxide doping 4-10 mol%, preferably the second doping for 10 mol% scandium oxide-ZrO₂Phase stabilization of (a); ni-doped ceria (e.g. Gd or Sm doped); ni and doped lanthanum chromate cermets (e.g., Ca doping at a sites and Zn doping at B sites); cermet of Ni and doped strontium titanate (e.g. La doping at A site and Mn doping at B site) and/or La_{1- x}Sr_xMn_yCr_1-yO₃. In other embodiments, the anode current collector may be formed from a cermet that is based at least in part on one or more noble metals and/or one or more noble metal alloys in addition to maintaining the Ni content. The noble metal in the cermet may include, for example, Pt, Pd, Au, Ag, and/or alloys thereof. The ceramic phase may include, for exampleInactive non-conductive phases including, for example, YSZ, ScSZ, and/or one or more other inactive phases, for example, having a desired Coefficient of Thermal Expansion (CTE) to control the CTE of the layer to match the CTE of the substrate 2110 and electrolyte 2130 c. In some embodiments, the ceramic phase may include Al₂O₃And/or spinel such as NiAl₂O₄、MgAl₂O₄、MgCr₂O₄Or NiCr₂O₄. In other embodiments, the ceramic phase may be electrically conductive, such as doped lanthanum chromate, doped strontium titanate, and/or one or more forms of LaSrMnCrO. One specific example of a material for anode current collector 2130a is NiO-NiAl₂O₄-8YSZ。

In this exemplary embodiment, anode 2130b is formed from xNiO- (100-x) YSZ (x is 55 to 75 weight percent), yNiO- (100-y) ScSZ (y is 55 to 75 weight percent), NiO-gadolinia stabilized ceria (e.g., 55 wt% NiO-45 wt% GDC), and/or NiO samaria stabilized ceria. In other embodiments, anode 2130b can be made of doped strontium titanate, La_1-xSr_xMn_yCr_1-yO₃(e.g., La)_0.75Sr_0.25Mn_0.5Cr_0.5O₃) And/or other ceramic-based anode materials.

In this exemplary embodiment, electrolyte 2130c is formed of a ceramic material. In some embodiments, electrolyte 2130c is formed of a proton and/or cation conducting ceramic. In other embodiments, electrolyte 2130c is formed of YSZ, e.g., 3YSZ and/or 8 YSZ. In other embodiments, electrolyte 2130c is formed of ScSZ, e.g., 4ScSZ, 6ScSZ, and/or 10ScSZ, in addition to or in place of YSZ. In other embodiments, electrolyte 2130c may be formed of doped ceria and/or doped lanthanum gallate. Electrolyte 2130c substantially does not allow oxidant (e.g., air or O) to flow through or past fuel cell tube 2100₂) And fuel (e.g. H)₂) Through which diffusion of oxygen ions and/or protons is permitted, depending on the particular embodiment and its application.

In this exemplary implementationIn an embodiment, cathode 2130d is formed from a mixture of an electrochemically catalytic ceramic and an ionic phase. The electrochemical catalytic phase is composed of LSM (La)_1-xSr_xMnO₃X ═ 0.1 to 0.3), La_1-xSr_xFeO₃(e.g., x ═ 0.3), La_1-xSr_xCo_yFe_{1- y}O₃(e.g., La)_0.6Sr_0.4Co_0.2Fe_0.8O₃) And/or Pr_1-xSr_xMnO₃(e.g., Pr)_0.8Sr_0.2MnO₃) Although other materials may be used. For example, in some embodiments, cathode 2130d is made of Ruddlesden-Popper nickelate and La_1-xCa_xMnO₃(e.g., La)_0.8Ca_0.2MnO₃) The material is formed. The ionic phase may be YSZ, which contains 3-8 mole% yttria; or ScSZ containing 4-10 mole% scandia and optionally a low content (about 1 mole%) of a second dopant of Al, Y or ceria for high scandia stabilized zirconia (8-10 ScSZ) to prevent the formation of the rhombohedral phase. The electrochemically catalytic ceramic phase may comprise 40-60% of the volume of the cathode.

In this exemplary embodiment, cathode current collector 2130e is an electrode conductive layer formed from a conductive ceramic and is in many cases similar in its chemistry to the electrochemically catalytic ceramic phase of the cathode. For example, a LSM + YSZ cathode will typically employ LSM (La)_1-xSr_xMnO₃And x ═ 0.1 to 0.3) a cathode current collector. Other embodiments of cathode current collector 2130e may include LaNi_xFe_1-xO₃(e.g., LaNi)_0.6Fe_0.4O₃)、La_1-xSr_xMnO₃(e.g., La)_0.75Sr_0.25MnO₃) Doped lanthanum chromite (e.g. La)_1-xCa_xCrO_3-δX is 0.15-0.3) and/or Pr_1-xSr_xCoO₃Such as Pr_0.8Sr_0.2CoO₃At least one of (1). In other embodiments, cathode current collector 2130e may be formed of a noble metal cermet. The noble metal in the noble metal cermet may include, for example, Pt, Pd, and,au, Ag and/or alloys thereof. May also include non-conductive ceramic phases, e.g., YSZ, ScSZ, and Al₂O₃Or other ceramic material. One specific example of a material for cathode current collector 2130e is (La)_0.8Sr_0.2)_0.95MnO_x。

In this exemplary embodiment, the fuel cell 2130, the laterally segmented simulated cells 2180 and 2185, and the laterally segmented fuel cells 2181, 2186, 2190, and 2195 are formed by: films/layers are deposited on the upper and lower major surfaces 2110a and 2110b of substrate 2110 by, for example, screen printing and/or ink jet printing to form a porous anode barrier layer, a primary interconnect, an anode current collector and anode, an electrolyte, a cathode, and a cathode current collector. In other embodiments, the film/layer may be deposited by one or more other techniques in addition to or instead of screen printing and/or inkjet printing. In various embodiments, one or more firing/sintering cycles are performed after deposition of one or more films/layers. Other embodiments may not require any firing/sintering for one or more film/layer depositions.

Fig. 11A and 11B are schematic diagrams showing a top view of the fuel cell tube 2100. Figure 11A shows a schematic of the anode side of a fuel cell tube including tube interconnect connection regions at laterally segmented analog cell portions 2180a and 2180 b. The laterally segmented analog cell portions 2180a and 2180b are electrically connected to the laterally segmented fuel cell portions 2181a and 2181b, respectively, via primary interconnects within the laterally spaced primary interconnect regions 2111. The primary interconnect region 2111 between the laterally segmented simulated cell portion and the laterally segmented fuel cell portion is laterally separated. The lateral segments extend into the primary interconnect region 2111 connected to the analog cell 2180 and into the fuel cell 2181 to allow electrical isolation of the fuel cell in operation. The laterally segmented fuel cell portions 2181a and 2181b are electrically connected to the fuel cell 2130 via primary interconnects within the primary interconnect region 2111. The fuel cell 2130 may be further electrically connected to the fuel cell 2130 via primary interconnects within the primary interconnect region 2111.

Fig. 11B shows a schematic of the cathode side of the fuel cell tubes, including the tube interconnect connection regions at the laterally segmented fuel cell portions 2190a and 2190B. The laterally segmented fuel cell portions 2190a and 2190b are electrically connected to the fuel cell 2130 via primary interconnects within the primary interconnect region 2111. The fuel cell 2130 may be further electrically connected to the fuel cell 2130 via primary interconnects within the primary interconnect region 2111 (not shown).

The addition of a laterally segmented fuel cell 2181 on the anode side of the fuel cell tubes, connected with a laterally segmented mock cell 2180, allows for the examination of the side-to-side and tube-to-tube connections of cells that have been operated and have a reduced anode in a Ni-cermet highly conductive state. These additions prevent erroneous readings when the cell is fired and there are cracked tube interconnects.

Fig. 11C and 11D are schematic diagrams showing a bottom view of the fuel cell tube 2100. Figure 11C shows a schematic of the anode side of a fuel cell tube including the tube interconnect connection region at the laterally segmented analog cell portions 2185a and 2185 b. The laterally segmented analog cell portions 2185a and 2185b are electrically connected to the laterally segmented fuel cell portions 2186a and 2186b, respectively, via primary interconnects within the primary interconnect region 2111. The primary interconnect region 2111 between the laterally segmented simulated cell portion and the laterally segmented fuel cell portion is laterally separated. The lateral segments extend into the primary interconnect region 2111 connected to the analog cell 2185 and into the fuel cell 2186 to allow electrical isolation of the fuel cell in operation. The laterally segmented fuel cell portions 2186a and 2186b are electrically connected to the fuel cell 2130 via primary interconnects within the primary interconnect region 2111. The fuel cell 2130 may be further electrically connected to the fuel cell 2130 via primary interconnects within the primary interconnect region 2111.

Fig. 11D shows a schematic of the cathode side of the fuel cell tube 2100, including the tube interconnect connection regions at the laterally segmented fuel cell portions 2195a and 2195 b. The laterally segmented fuel cell portions 2195a and 2195b are electrically connected to the fuel cell 2130 via primary interconnects within the primary interconnect region 2111. The fuel cell 2130 may be further electrically connected to the fuel cell 2130 via primary interconnects within the primary interconnect region 2111 (not shown).

the addition of a laterally segmented fuel cell 2186 on the anode side of the fuel cell tubes, connected with a laterally segmented mock cell 2185, allows for the examination of the side-to-side and tube-to-tube connections of cells that have been operated and have a reduced anode in a Ni-cermet highly conductive state. These additions prevent erroneous readings when the cell is fired and there are cracked tube interconnects.

Fig. 10-14 illustrate one exemplary embodiment of a fuel cell tube 2100 and its components of the present disclosure. Fuel cell tube 2100 includes a porous substrate 2110 having a width W, a length L, a thickness T, a substantially flat upper major surface 2110a and a substantially flat lower major surface 2110 b. The fuel cell tube 2100 can be fluidly connected to a manifold (not shown) that can be fluidly connected to a fuel source such that fuel can flow from the fuel source, through the manifold and into and through the fuel conduit 2110 c. In the exemplary embodiment, substrate 2110 is composed of MgO — MgAl₂O₄(MMA) although in other embodiments the substrate 2110 may be formed of any suitable material (e.g., doped zirconia and/or forsterite) in addition to or in place of MMA. The glass edge seal is not shown in fig. 12 in order to clarify the structure of the components below it. In fig. 13, the electrolyte 2130c, the first and second porous anode barrier layers 2120a and 2120b, and the substrate 2110 are indicated by dashed lines since they are behind the glass edge seal 2146.

First and second porous anode barriers 2120a and 2120b are disposed on the upper and lower major surfaces 2110a and 2110b, respectively, of substrate 2110. The first and second porous anode barriers 2120a and 2120b are configured to prevent reactions between the anode of a fuel cell (described below) and the substrate 2110 and are not configured to provide electrical conductivity within a given fuel cell or between two fuel cells. In addition, the first and second porous anode barriers 2120a and 2120b are not configured to participate in electrochemical reactions that generate electrical energy from the fuel. In this exemplary embodiment, the first and second porous anode barrier layers 2120a and 2120b are made of an inert porous ceramic material, such as 3YSZ or another suitable dopingAlthough in other embodiments the first and second porous anode barriers 2120a and 2120b may be formed of any suitable material, such as SrZrO, in addition to or instead of doped zirconia₃And (4) forming. In other embodiments, the fuel cell tube 2100 does not include the first and second porous anode barriers 2120a and 2120 b.

A plurality of fuel cells 2130, laterally segmented mock cells 2180, and laterally segmented fuel cells 2181 and 2190 are disposed on the first porous anode barrier 2120 a. Each of the fuel cells 2130, the transversely segmented simulated cells 2180, and the transversely segmented fuel cells 2181 and 2190 extend transversely in the direction of the width W of the base 2110 and terminate in opposite first and second transverse ends (not labeled). The fuel cell 2130 is positioned between the laterally segmented fuel cells 2181 and 2190, which laterally segmented fuel cells 2181 and 2190 are positioned at opposite ends closest to the first porous anode barrier layer 2120a, generally in the direction of the length L of the substrate 2110. The fuel cells 2130, the laterally segmented mock cells 2180, and the laterally segmented fuel cells 2181 and 2190 on the first porous anode barrier 2120a are electrically connected in series via primary interconnects within the primary interconnect region 2111.

As best shown in fig. 11A and 12, the laterally segmented simulated cell 2180 includes first and second simulated cell portions 2180a and 2180 b. The first and second analog cell portions 2180a and 2180b are electrically connected to the first and second fuel cell portions 2181a and 2181b, respectively, via primary interconnects within the primary interconnect region 2111. The first and second analog cell portions 2180a and 2180b are laterally separated in the width W direction of the substrate 2110 such that the first and second analog cell portions are electrically isolated. The analog battery parts 2180a and 2180b are separated by 1.5mm in the width W direction of the substrate 2110 so that there is no continuous direct electrical path therebetween. The main interconnect regions 2111 to which the analog cell portions 2180a and 2180b are connected are also separated by 1.5mm in the width W direction of the base 2110. As shown in fig. 14A, the space between the first and second simulated cell portions 2180a and 2180b includes a dense barrier layer 2120c covered by an electrolyte 2130 c.

As best shown in fig. 11A and 12, the inner laterally segmented fuel cell 2181 includes first and second fuel cell portions 2181A and 2181 b. The first and second fuel cell portions 2181a and 2181b are electrically connected to the fuel cell 2130 via primary interconnects within the primary interconnect region 2111. The first and second fuel cell portions 2181a and 2181b are laterally separated in the direction of the width W of the substrate 2110 so that the first and second fuel cell portions are electrically isolated. The fuel cell portions 2181a and 2181b are separated by a spacing of 1.5mm in the width W direction of the substrate 2110 so that there is no continuous direct electrical path therebetween.

As best shown in fig. 11B and 12, the laterally segmented fuel cell 2190 includes first and second fuel cell portions 2190a and 2190B. The first and second fuel cell portions 2190a and 2190b are electrically connected to the fuel cell 2130 via the primary interconnect within the primary interconnect region 2111. The first and second fuel cell portions 2190a and 2190b are laterally separated in the width W direction of the substrate 2110 such that the first and second fuel cell portions are electrically isolated. The fuel cell portions 2190a and 2190b are separated by 1.5mm intervals in the width W direction of the substrate 2110 so that there is no continuous direct electrical path between them. As shown in fig. 14B, the space between fuel cell portions 2190a and 2190B includes a dense barrier layer 2120c covered by an electrolyte 2130 c.

A plurality of fuel cells 2130, laterally segmented mock cells 2185, and laterally segmented fuel cells 2186 and 2195 are disposed on the second porous anode barrier 2120 b. Each of the fuel cells 2130, the laterally segmented simulated cells 2185, and the laterally segmented fuel cells 2186 and 2195 extend laterally substantially in the direction of the width W of the base 2110. The fuel cell 2130 is positioned between the laterally segmented fuel cells 2186 and 2195, which laterally segmented fuel cells 2186 and 2195 are positioned at opposite ends closest to the second porous anode barrier layer 2120b, generally in the direction of the length L of the substrate 2110. The fuel cells 2130, the laterally segmented mock cells 2185, and the laterally segmented fuel cells 2186 and 2195 on the second porous anode barrier 2120b are electrically connected in series via primary interconnects within the primary interconnect region 2111.

As best shown in fig. 11C and 14A, the laterally segmented simulated cell 2185 includes first and second simulated cell portions 2185a and 2185 b. The first and second analog cell portions 2185a and 2185b are electrically connected to the first and second fuel cell portions 2186a and 2186b, respectively, via primary interconnects within the primary interconnect region 2111. The first and second analog cell portions 2185a and 2185b are laterally separated in the width W direction of the substrate 2110 such that the first and second analog cell portions 2185a and 2185b are electrically isolated. The first and second analog battery parts 2185a and 2185b are separated by an interval of 1.5mm in the width W direction of the substrate 2110 so that there is no continuous direct electrical path therebetween. The main interconnect regions 2111 to which the analog cell portions 2185a and 2185b are connected are also separated by 1.5mm in the width W direction of the base 2110. As shown in fig. 14A, the space between the simulated cell portions 2185a and 2185b includes a dense barrier layer 2120c covered by an electrolyte 2130 c.

As best shown in fig. 11C, the inner laterally segmented fuel cell 2186 includes first and second fuel cell portions 2186a and 2186 b. The first and second fuel cell portions 2186a and 2186b are electrically connected to the fuel cell 2130 via a primary interconnect within the primary interconnect region 2111. The first and second fuel cell portions 2186a and 2186b are laterally separated in the direction of the width W of the substrate 2110 so that the first and second fuel cell portions 2186a and 2186b are electrically isolated. The first and second fuel cell portions 2186a and 2186b are separated by a spacing of 1.5mm in the width W direction of the substrate 2110 such that there is no continuous direct electrical path therebetween

As best shown in fig. 11D and 14B, the laterally segmented fuel cell 2195 includes first and second fuel cell portions 2195a and 2195B. The first and second fuel cell portions 2195a and 2195b are electrically connected to the fuel cell 2130 via primary interconnects within the primary interconnect region 2111. The first and second fuel cell portions 2195a and 2195b are laterally separated in the width W direction of the substrate 2110 such that the first and second fuel cell portions 2195a and 2195b are electrically isolated. The first and second fuel cell portions 2195a and 2195b are separated by 1.5mm in the width W direction of the substrate 2110 so that there is no continuous direct electrical path between them. As shown in fig. 14B, the space between fuel cell portions 2195a and 2195B includes a dense barrier layer 2120c covered by an electrolyte 2130 c.

As shown in fig. 14A, the first fuel cell connector 2145a is electrically connected to (and electrically connects) the first analog cell portion 2180a of the laterally segmented analog cell 2180 and the first analog cell portion 2185a of the laterally segmented analog cell 2185. As shown in fig. 13 and 14A, a second fuel cell connector 2145b is electrically connected to (and electrically connects) a second analog cell portion 2180b of the laterally segmented analog cell 2180 and a second analog cell portion 2185b of the laterally segmented analog cell 2185.

In this exemplary embodiment, a first fuel cell connector 2145a is electrically connected to (and in this exemplary embodiment contacts) the cathode current collectors of the first analog cell portions 2180a and 2185a, and a second fuel cell connector 2145b is electrically connected to (and in this exemplary embodiment contacts) the cathode current collectors of the second analog cell portions 2180b and 2185 b. Since the first and second analog cell portions 2180a and 2180b are electrically isolated and the first and second analog cell portions 2185a and 2185b are electrically isolated, the first and second fuel cell connectors 2145a and 2145b are electrically isolated such that there is no continuous electrical path across the width W of the substrate 2110. The glass edge seal 2146 fills the gap between the fuel cell connector 2145a and the rest of the fuel cell tube 2100. The glass edge seal 2146 extends down the entire length of the fuel cell tube 2100 and prevents fuel from escaping the fuel cell structure, separating air and fuel. The glass edge seal 2146 also fills the gap between the fuel cell connectors 2145b and the rest of the fuel cell tube 2100. The glass edge seal 2146 extends down the entire length of the fuel cell tube 2100 and prevents fuel from escaping the fuel cell structure, separating air and fuel.

As shown in fig. 14B, the third fuel cell connector 2155a is electrically connected to (and electrically connects) the first fuel cell portion 2190a of the laterally segmented fuel cell 2190 and the first fuel cell portion 2195a of the laterally segmented fuel cell 2195. As shown in fig. 13 and 14B, the fourth fuel cell connector 2155B is electrically connected to (and electrically connects) the second fuel cell portion 2190B of the laterally segmented fuel cell 2190 and the second fuel cell portion 2195B of the laterally segmented fuel cell 2195.

In this example embodiment, third fuel cell connector 2155a is electrically connected to (and in this example embodiment contacts) the cathode current collectors of first fuel cell portions 2190a and 2195a, and fourth fuel cell connector 2155b is electrically connected to (and in this example embodiment contacts) the cathode current collectors of second fuel cell portions 2190b and 2195 b. Since the first and second fuel cell portions 2190a and 2190b are electrically isolated and the first and second fuel cell portions 2195a and 2195b are electrically isolated, the third and fourth fuel cell connectors 2155a and 2155b are electrically isolated such that there is no continuous electrical path across the width W of the substrate 2110. The glass edge seal 2146 fills the gap between the fuel cell connector 2155a and the rest of the fuel cell tube 2100. The glass edge seal 2146 extends down the entire length of the fuel cell tube 2100 and prevents fuel from escaping the fuel cell structure, separating air and fuel. The glass edge seal 2146 also fills the gap between the fuel cell connector 2155b and the rest of the fuel cell tube 2100. The glass edge seal 2146 extends down the entire length of the fuel cell tube 2100 and prevents fuel from escaping the fuel cell structure, separating air and fuel.

Fig. 15A and 15B show three fuel cell tubes 2100, 2200, and 2300 of the fuel cell stack 20. Although the fuel cell stack 20 may include an appropriate number of fuel cell tubes electrically connected in series with one another, only three are shown here for clarity and brevity. In this example embodiment, fuel cell tubes 2200 and 2300 are identical to fuel cell tube 2100 and therefore are not described separately (although in other embodiments the fuel cell tubes may be different from each other). The element numbering scheme of fuel cell tubes 2200 and 2300 corresponds to the element numbering scheme used to describe fuel cell tube 2100, such that like element numbers correspond to like components.

As shown in fig. 15A, the first fuel cell tube 2100 is electrically connected to the second fuel cell tube 2200 via: (1) a first tube interconnect 2122a that electrically connects the fuel cell connector 2145a of the first fuel cell tube 2100 to the fuel cell connector 2255b of the second fuel cell tube 2200; and (2) a second tube interconnect 2122b that electrically connects the fuel cell connector 2145b of the first fuel cell tube 2100 to the fuel cell connector 2255a of the second fuel cell tube 2200. The first tube interconnect 2122a electrically connects the transversely segmented analog cell portions 2180a and 2185a of the first fuel cell tube to the transversely segmented fuel cell portions 2290b and 2295b of the second fuel cell tube. A second tube interconnect 2122b electrically connects the laterally segmented analog cell portions 2180b and 2185b to the laterally segmented fuel cell portions 2290a and 2295 a. Typically, the fuel cell tubes are connected in series along the direction of fuel flow through the tubes.

As shown in fig. 15B, the second fuel cell tube 2200 is electrically connected to the third fuel cell tube 2300 via (1) a third tube interconnect 2223a, which electrically connects the fuel cell connector 2245a of the second fuel cell tube 2200 to the fuel cell connector 2355B of the third fuel cell tube 2300; and (2) fourth tube interconnects 2223b that electrically connect the fuel cell connectors 2245b of the second fuel cell tubes 2200 to the fuel cell connectors 2355a of the third fuel cell tubes 2300. Third tube interconnect 2223a electrically connects the transversely segmented analog cell portions 2280a and 2285a of the second fuel cell tubes to the transversely segmented fuel cell portions 2390b and 2395b of the third fuel cell tubes. Fourth tube interconnect 2223b electrically connects the transversely segmented analog cell portions 2280b and 2285b of the second fuel cell tubes to the transversely segmented fuel cell portions 2390a and 2395a of the third fuel cell tubes.

The tube interconnects shown in the various embodiments (e.g., 2122a and 2122b in fig. 15A) are depicted as wires for exemplary purposes only. The present disclosure is suitable for other designs for pipe (secondary) interconnections, such as the designs disclosed in the following co-pending applications: U.S. patent application No. 15/816,918 entitled "Improved Fuel Cell secondary interconnect" filed on 17.11.2017; U.S. patent application No. 15/816,931 entitled "improved fuel Cell Secondary Interconnect," filed on 17.11.2017; and U.S. patent application No. 15/816,948 entitled "Multiple Fuel Cell Secondary Interconnect Bonding Pads And Wires", filed on 17.11.2017.

Various modifications to the embodiments described herein will be readily apparent to those skilled in the art. Such modifications can be made without departing from the spirit and scope of the present disclosure and without diminishing its intended advantages. It is contemplated that these changes and modifications are covered by the appended claims.